Carpet tufting and pile cutting device



April 8, 1952 T. K. HOLMEN CARPET TUFTING AND PILE CUTTING DEVICE 4Sheets-Sheet 1 Filed Oct. 12, 1950 H. E f J 2. v.

INVENTOR. TOR LEl F K. HOLM EN. BY

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ATTORNEYS.

April 8, 1952 T. K. HOLMEN CARPET TUFTING AND FILE CUTTING DEVICE 4Shets-Sheet 2 Filed Oct. 12, 1950 INVENTOR- TORLEI F K. HOLMEN. BY

A TTOANEVJ.

April 8, 1952 T. K. HOLMEN 2,591,939

CARPET TUFTING AND PILE CUTTING DEVICE Filed Oct. 12, 1950 4Sheets-Sheet 5 INVENTOR.

TOELEI F K. HOLMEN.

A ORA 5K5.

April 8, 1952 T. K. HOLMEN CARPET TUFTING AND PILE CUTTING DEVICE 4Sheets-Sheet 4 Filed Oct. 12, 1950 TtiflR LEIF K.HOL MEN.

7 ZQ QXM ATTORNFKS'.

Patented Apr. 8, 1952 2,591,939 CARPET TUFTING AND PILE CUTTING DEVICE ITorleif K. Holmen, Brooklyn, N. Y., assignor to Rugcrofters, Inc., NewYork, N. Y., a corporation of New York Application October 12, 1950,Serial No. 189,719

This invention pertains to improvements in the manufacture of tufted andpile cut fabrics, more specifically tufted and pile cut carpet.

The invention comprises essentially a stepper and cutter assembly, usedin conjunction with a needle, for producing successive tufts offilamentary material in a base fabric, and for cutting said tufts asthey are formed, to provide a resulting tufted fabric having a cut pile.

The needle andthe stepper and cutter mechanism are adapted to be poweractuated in appropriately timed relation by a mechanism similar to thatdescribed in a copending application of R. C, Kline, Serial No. 148,946,filed March 10, 1950, sufficient disclosure of which is included in thisapplication to describe andillustrate operation of the present inventionin conjunction therewith.

In a copending application of R. C. Kline and J. Miller, Serial No.128,314, filed November 19, 1949, there is described a power drivencarpet tufting mechanism, comprising an eccentrically driven needle, andcooperating cam actuated stepper. In this mechanism, the filamentarymaterial to be tufted in successive loops through a base fabric, is fedthrough the needle. which, as stated, is eccentrically driven,successively to penetrate and be withdrawn from the base fabric inprogressive stitches. The cam actuated stepper is ablade having a, Vnotch at its advancing end-which follows up the needle on each stitch,and catches and. holds the stranded material in its V notch as theneedle is withdrawn, thus to. form the loop or tuft on each stitch, thestepper being thereupon withdrawn from the base fabric, to similarlyfollow up the needle on the next stitch.

In said R. C. Kline application Serial, No. 148,946, the stepper takesthe form of a pair of resilient blades, mounted face-to-face, andnormally terminating beneath the needle point, in oppositely beveledends, to provide a V notch i therebetween. The stepper blades areindependently actuated by separatepower driven cams, being slidablydisplaceable with respectflto each other, at an appropriate portion ofthe tufting cycle for cutting each tuft as it is formed, the cycle ofoperation being as follows: The needle is eccentrically driven asbefore, and as it is advanced through the base fabric, it carries withit the fila-,- mentary material fed through the needle hole. The stepperfollows up the needle, the two blades thereof being actuated in unison,to catch the filamentary material in the V notch between-the, bladcaandto hold the filament and form the tuft 5 Claims. (Cl. 112 79) as theneedle is withdrawn. After the tuft is thus formed, one stepper blade isslidably displaced with respect to the other, by virtue of theindependent cam drives referred to, whereby the tuft is pile'cut, byshearing action, due to advancement of one stepper blade relative to theother.

According to the mechanism of the present invention, an entirelydifferent principle of construction and operation is'employed for thestepper and cutter mechanism and for formingthe tufts and pile cuttingeach tuft as it is formed.

In its broader aspect, the stepper and cutter mechanism of the presentinvention comprises a pair of elongated and flattened metal bars orstrips, preferably sulmtantially rectangular in cross section. One ofsaid bars has integral therewith, adjacent one end, a tubular sheath,while the second bar has a terminal portion slidable within said sheath,and has secured thereto a longitudinally beveled knife blade. A pair ofspaced prongs project beyond the sheath, forming therebetween alongitudinally extending slot for catching and looping a standedmaterial to be out. After the loop is thus formed, the second bar isdisplaceable within the sheath, whereby the knife blade secured thereto,severs the stranded material looped through the slot, by what may aptlybe referred to as a slicing-in-two action.

More specifically, in accordance with one modie fication thereof, theinvention comprises a stepper and a cutter element. The steppercomprises, in essence, a flattened, tubular sheath, longitudinallyslotted atone end to provide opposed prongs, spaced by a substantiallyU-shaped slot, for catching and looping the stranded material to betufted and cut, this sheath having integral with and projecting from theopposite end thereof, an elongated bar or metal strip, for reciprocatingthe same from a power driven cam. The cutter element comprises a bar ormetal strip having a terminal portion which is slidable within thestepper sheath, this portion terminating in a longitudinallybeveledknife edge, adapted upon displacement of thecutter bar relativeto the stepper, to sever the stranded material looped through thestepper slot, the cutting action in this case comprising, as stated, aslicing in two" of the tuft, in contrast to the shearing cutting actioneffected with the two blade stepper assembly of thecopending Klineapplication aforesaid. In accordance with a second modification of theinvention, separate and distinct stepper and cutter elements are notemployed, but two components are utilized which by their conjoint ac- 3tion, provide the stepper and cutter operations.

In accordance with a preferred embodiment of this modification of theinvention, the stepper and cutter mechanism comprises a pair ofelongated and flattened bars, preferably substantially rectangular incross section. A first said bar has integral therewith a flattened,tubular sheath, surrounding the same adjacent one end; while the secondsaid bar has a terminal portion slidable within the sheath in edgewiseengagement with the first bar. The first and second bars project,respectively, beyond the sheath, in spaced prongs, forming therebetweena longitudinally extending slot for catching and looping the strandedmaterial to be tufted and cut. The second bar is longitudinally groovedalong an intermediate portion of its inner edge, this groove terminatingat one end in a V notch, and having a pointed, longitudinally beveledknife blade, detachably mounted in the groove, with the point thereofengaging the V notch. The second bar is longitudinally groovedthroughout its inner edge, for slidable reception of the knife blade. Inthis modification also the knife blade is adapted upon longitudinaldisplacement of the second bar with respect to the first bar, to severstranded material looped through said slot.

The carpet tufting and pile cutting cycle of operations with themechanism of the present invention is generally similar to thatdescribed above with reference to said Kline application Serial No.148,946. The needle is eccentrically driven, and first advances into thebase fabric carrying with it the filamentary material, fed through theneedle hole. The stepper and cutter assembly is thereupon advanced, as aunit, by separate cams, mounted on the cam shaft which drives the needleeccentric. During the initial advance of the stepper and cutterassembly, the knife edge is in a retracted position within the sheath ofthe stepper and cutter mechanism so that-as this assembly follows up theneedle, the stranded material is caught in the slot thereof, and heldthere as the needle is withdrawn, to form the tuft. Thereupon the knifeedge is advanced,

relative to the slot, thus to sever the tuft, thereby to pile out eachtuft as it is formed, thus to produce a tufted and pile cut fabric. Assoon as the tuft has been cut, the knife edge is again retracted by itscam within the sheath, and the stepper and cutter assemblage Withdrawnas a unit, to follow up the needle, and provide the same cycle ofoperations on the next tufting stitch.

Referring now to the drawings:

Figure 1 is a plan view of a stepper and cutter assembly in accordancewith the first modification of the invention above mentioned, whileFigure 2 is a side elevation thereof. Figure 3 is an enlarged plan view,similar to F gure 1, but with a portion of the stepper sheath cut awayto show the terminal construction of the cutter element disposed withinthe sheath. Figure 4 is a longitudinal section taken at 4-4 of Figure 3,while Figure 5 is a longitudinal section taken at 5-5 of Figure 3.Figure 6 is an enlarged end elevation of the Figure 1 assembly as viewedfrom the left in the drawing.

Figures 7, 8 and 9 are respectively a plan view, a side elevation, andan end elevation, the latter as viewed from the left in Figure 7, of astepper and cutter assembly in accordance with the second modificationof the invention, which includes a detachably mounted knife. Figure 10is an enlarged plan view, similar to Figure 7, with a portionof the"sheath removed, to "illustratethe' detachable mounting of the knife.Figure 11 is a plan view, partly in section, of the terminal portion ofthe bar on which the knife is mounted, further illustrating thedetachable mounting of the knife edge therein. Figure 12 is an elevationof Figurell as viewed from below in Figure 11. Figures 13, 14 and 15 aretransverse sections, as taken at I3I3, I l-I4, and I5I5, respectively,of Figure 10. Figure 16 is a longitudinal section as taken at I6--I 6 ofFigure 10.

Figure 17 is a side elevation, partly in section, of the above mentionedeccentric and cam actuating mechanism for driving the needle and stepperand cutter elements, as aforesaid, to produce a tufted and pile cutfabric; while Figure 18 is cross section thereof taken at I8I8 of Figure17. Figure 19 is a plan view, partly in section and partly in elevation,as taken approximately along the line I9-I 9 of Figure 18.

Figures 20 to 23 inclusive are side elevations, partly in section, ofthe needle and stepper and cutter mechanisms, at successive intervals ofthe tufting and pile cutting cycle, to illustrate the relative positionsof these components at various portions of said cycle; while Figures 24and 25 are fragmentary plan views of the stepper and cutter elementsshowing the relative positions thereof, at the Figures 22 and 23intervals respectively of the tufting and pile cutting cycle.

Referring to the modification of the invention illustrated in Figures 1to 6 inclusive, there is shown a stepper and cutter assembly I, thestepper of which comprises a flattened, substantially rectangular,tubular sheath 2, which is longitudinally slotted at one end, as at 3,to provide opposed prongs 4, 5, spaced by a substantially U-shaped slot6, the latter for the reception of the stranded material to be tuftedand cut. Integral with and extending from the opposite end of the sheath2 is a bar or metal strip 1, for longitudinally displacing the stepperby the power actuating mechanism in the manner described below. Alsomounted on the underside of the stepper bar I is a lug 8, preferablyprovided with a toothed or serrated face, as at 9, perpendicular to theplane of the bar I, for engaging the base fabric and regulating thedepth of penetrattion of the stepper therethrough, in the mannerexplained below. The cutter comprises a separate bar or metal strip I0,having a terminal portion II adapted to slide within the stepper sheath2, this terminal portion having mounted thereon or formed integraltherewith, a pointed blade I2, having a longitudinally beveled knifeedge, as at I3.

Referring more particularly to Figures 4, 5 and 6, the oppositesidewalls I3a, I4 of the sheath prong 4, are substantially parallel, asshown, while the sidewalls I5, I6, of the opposite sheath prong 5 areinclined toward each other, to facilitate the cutting action, as theknife blade I2 is longitudinally displaced with respect to the slot 6.The terminal ends of the metal strips 1 and I0, are provided with holesas at IT, I8, for mounting on thrust bars of the cam actuatedrereciprocating mechanism as described hereinafter.

To describe briefly at this point the operation of this stepper andcutter mechanism, the cutter bar I0 is normally in the position shown inFigures 1 to 6, in relation to the stepper assembly 2, I. For thetufting operation, the stepper and cutter assembly, in their relativepositions shown, are advanced as a unit; whereby the stranded materialto be tufted andlpile cut, is caught'in mousse the slot 8 and loopedthereover'under tension.

Thereupon the cutter bar In is advanced relative to the stepper, 2, 1 sothat the beveled knife edge |3 of the knife blade I2 severs the strandedmaterial by a slicing action, whereupon the cutter bar In is againretracted to the position shown in the drawing. During the cuttingaction the stranded material is pressed by the knife edge l3 against theinwardly inclined walls |5, |6 of the lower" prong thus facilitatingsevering of the'stra'nd' by slicing action.

Referring to the modification of the invention shown in Figures? to 16inclusive. the mechanism comprises a first bar or metal strip 20, one

- end 2| of which is relatively narrow and coplanar,

whilethe opposite end 22 is widened and bent away from, as at 23, andthence'substantially parallel, as at 24, to the plane of portion 2|, andfinally inclined thereto, as at 25. Portion 2| is further narrowed atits end and pointed at its.

and slidably mounted in the remaining portionof the sheath, is a secondbar ormetal strip 29, which is of substantially constant width andcoplanar throughout its length, except for its end 30 which is widenedand inclined substantially parallel to the end 22 of bar 20. Also theopposite end of bar 29 is further narrowed and pointed at its extremityas at 3|, to providea.

terminal prong 32, similar to and spaced from prong 21 of bar 20, andforming therebetween a' slot 33, which is terminated by the outer edge34 of sheath 28. The bars 20, 29, are normally in the relative positionsshown in the drawings, with their pronged ends projecting from thesheath to the same extent, prong 21 being as explained fixed relative tothe sheath, while prong 32 isdisplaceable relative thereto, due to" thefact that bar 29 is slidably displaceable in the sheath in edgewiseengagement with portion 2| of bar 20.

As shown more particularly in Figures 11 and 12, the inner edge of bar29 is --longitudinally slotted for an intermediate extent adjacentitspronged end, as at 35, the slot terminating at its forward end in a Vnotch, as at 36, and having a substantially right angled terminus at itsopposite end, as at 36a.

Detachably mounted in this slot is a knife blade 31, having a pointedend 38 seated in the V notch 36, and having a longitudinally beveledcutting edge 39, ending in a right angled terminus 40, which abuttinglyengages the slot end 36a. The end 48 is provided with a small bore, asat 4| for insertion of a bar, as at 42, for removing and replacing theblade in the manner illustrated by the dashed line position 43 of theblade.

Itwill be observed that the blade 31 projects beyond the bar 29 in whichit is mounted, and to permit of slidably displacing the bar 29 and blade31 with respect to bar 20, the latter is longitudinally grooved alongits inner edge, as at 44, throughout the length of the narrow portion 2|thereof, as shown most clearly in Figure 16. The projecting portion ofblade 31 slides within this groove, and the arrangement permits ofcompletely withdrawing bar 29 andblade 31 assembled thereon fromengagement with the sheath 28 and bar 28, for purposes of disassembly.

Figures 1'7 to 19 inclusive show a power driven carpet tufting and pilecutting mechanism embodying the invention. Since this mechanism. isgenerally similar to that fully described and claimed in said Klineapplication Serial No. 148,946, except for the requisite. modification.to.

incorporate the stepper and cutter mechanism of the present invention,itsconstruction and opera-.-

tion will be described only in suflicient detail to describe itsoperation in relation to the present invention.

The mechanism comprises three thrust bars 50,-5l and 52, mounted. forslidable displacement along parallel paths in a housing 54, and in themanner clearly shown in the sectional view, Fig-. ure 18. Bar 50 isreciprocatively driven by means of an eccentric arm 55, pivoted thereto,as at 56, and an eccentric 51, to which arm 55 is in turn pivoted, as at58.

having the configurations shown in Figure 17', which respectivelyreciprocate the thrust bars, 5|, 52, through link connections 63, 64, towhich are journaled cam rolls 65, 66, respectively engag-; ing theperipheral'faces of cams 61,62, The cam trolls are maintained inresilient engagement with the cam faces, by means of coiled springs,-such as 61, and link members, such as 68, piv-.

otally mounted, as at 69, in a housing 18. The

link members 68, are pivoted to the link members 63, 64, as at 68a,while the springs 61 are provided with lever arms 1|, operating betweenstuds 12, 13, fixed to the housing 18 and link members 68 respectively.Mounted on housing 54, is a ring guard 14, adjustably spaced therefrom.by a

nut 15.

With the modificationof the invention shown in Figures 1 to 6 inclusive,the stepper and cut-;

ter bars 1 and ID, are respectively mounted by screws passing throughthe screw-holes |1, .|8,-

on the thrust bars 52, 5|, and in the manner shown at 16, 11, of Figure18. Cooperating with these stepper and cutter elements, is a needle 18,

mounted on a lug 19, secured to the underside of thrust bar 58. Yarn B9,to be tufted, as at 8|, into a base fabric 82, and thereupon pile cut,as at 82a, is fed through an eyelet 83, mounted on frame 54, and thencethrough the needle hole;

as at 84. 1

In the operation of this mechanism, rotation of shaft 59, reciprocatesthe thrust bars 58-52 inclusive in appropriately timed relation throughthe intermediary of the eccentric and cam drives referred to. thesequence of operation being as illustrated in Figures 20 to 25inclusive. Figure 20 shows the first step with the needle 18 penetratingthe base fabric 82, carrying with it the yarn to form the loop or tuft,the stepper and cutter element 16, 11 being in the retracted positionshown. In Figure 21, the needle has penetrated the fabric to the fullextent, and the stepper and cutter elements have likewise followed upthe stepper to the full extent, being advanced as a unit by theconfluent face portions 85, Fig

The eccentric is keyed to a. power driven shaft 59, journaledin bearings68.. Also keyed to shaft 59, are a pair of cams 6|, 82,

7, rolls", 52, Figure. 17. In2Figurev23;therknife 88 is beingiadvancedrelative toxthe stepper. in the manner shown in Figure, 25, to. severthe yarn looped,. as inFigureZ, over; the, base of slot. 89, thusto.pile cut theyarn-as at 89, 90,

Figure 23. This relative displacement of the cutter andstepper elements.is effected by-the. non-confluent. cam face portions 91', 92,.Figuretrated in Figures 7. to 16 inclusive-the same se--v quence: occursexcept that: now bars 20' and 29 of this modification. arerespectively-mounted as at,16,,|'|- inthe thrust bars--52. 5|.

What is claimed is:

1. Inv combination'a stepper and cutterfor producing a tufted and pilecut fabric, saidstepper comprising a flattened, tubularsheathlongitudinally slotted atone end to'provide opposed prongs, eachof substantially U-shapenin transverse section forreception of astranded-material to be tufted" and cut, and a bar integral with andprojecting from the opposite end of said sheath, said cutter comprisinga bar having a terminal portion slidable within said. sheath,

said terminal portion including a. beveled knife edge, adapted upondisplacement thereof relative to said sheath, to sever strandedvmaterial held in said slot.

2. In combination a stepper and cutter for producing a tufted and pilecut fabric, said stepper comprising a flattened, tubular sheath,longitudinally slotted at oneendxto provide opposed prongs, each ofsubstantially U-shape in transverse section for reception of a strandedmaterial to be tufted and cut, and abar integral with and projectingfrom the opposite end of saidv sheath, said cutter comprising a barhaving a terminal portion slidable within said sheath, said terminalportion including a beveled knife edge, adapted upon displacementthereof relative to said sheath, to sever stranded material held insaidslot, said stepper also having integral with said sheath a fabricengaging lug, for regulating the depth of penetration of said stepperthrough the fabric.

3. In combination a stepper and cutter as sembly. for producing a tuftedand pile cut fabric, said stepper comprising a flattened, tubularsheath, longitudinally slotted at one end to. provide opposed prongs forcatching and looping a stranded material to be tufted and cut, each ofsaid prongs being substantially U-shaped in.

transverse section, the opposed legs of one of which are inclined towardeach other, and a bar integral with and projecting from the opposite endof said sheath, and said cutter comprising a bar having a terminalportion slidable within; said sheath.. said terminalportion.vincludingaa, pointed knife edge, of longitudinally beveledconfiguration, adapted upon longitudinal displacement thereof relativeto said: sheath, to sever stranded material looped through said stepperslot, the aforesaid inwardlyinclined legs of said stepper prong forminga two point support for the stranded material between which supportssaid knife edge severs said stranded material withoutengaging; saidinwardly inclined prong legs.

4. .A combined cutter and stepper mechanism forproducing a tufted andpile cut fabric, comprising: a pair ofelongated and flattened bars, afirst said barhaving integral therewith, adjacentone end, a flattened,tubular sheath, the

second said bar having, aterminal portion slid-- able within said sheathand having secured thereto a longitudinally beveled knife blade a pairof prongs projecting beyond said sheath and forming therebetween alongitudinally extending slot for catching and looping a stranded.material to be tufted and cut, at least one of said prongs beingintegral with said sheath, and being of substantially U-shape intransverse section for slidable reception of said knife blade, and saidsecond bar being displaceable in said sheath for severing said strandedmaterial so caught and looped.

5. A combined cutter and stepper mechanism for producing a tufted andpile cut fabric, comprising: a. pair of elongated and flattened bars,

catching and looping a stranded material to betufted and cut, the secondsaid bar having secured to the inner face thereof, adjacent said prongedend, and normally disposed within said sheath, a longitudinally beveledknife blade, and the pronged end of the first said bar being ofsubstantially U-shape in transverse section for slidable reception ofsaid knife blade, and said second bar being displaceable in said sheathfor severing said stranded material so caught. and looped.

TORLEIF K. HOLMEN.

REFERENCES CITED The following references are of record inthe file ofthis patent:

UNITED STATES PATENTS Number Name Date 1,905,637 Howe Apr. 25, 19331,976,709 Doubler Oct. 16, 1934 2,057,920 Rose Oct. 20, 1936

